Wall stud system

ABSTRACT

A wall stud system comprising a plurality of horizontal floor and ceiling beams arranged in parallel spaced relationship and a plurality of vertical hollow studs extending between the floor and ceiling beams. Each stud is formed to a similar crosssectional configuration and each floor and ceiling beam is provided with vertically aligned openings to receive the top and bottom of the studs therein. Each aligned opening is positioned in rotative angular relation to the final position of the stud when installed. The studs are provided with wedge-shaped notches at all corners about the periphery of the stud near the tops and bottoms thereof to lock each stud into the beam material after insertion and rotation through the predetermined angle.

United States Patent 1 Brenner 1 1 June 5,1973

[54] WALL STUD SYSTEM [22] Filed: A lr. 26, 1971 [2]] Appl. No.1 150,870

[52] US. Cl. ..52/300, 52/667, 52/298,

248/188, 287/103 A [51] Int. Cl. ..E04h 12/22 [58] Field of Search..52/300, 301, 241,

' Primary ExaminerFrank L. Abbott Assistant Examiner-Carl D. FriedmanAttorney-Karl L. Spivak [57] ABSTRACT A wall stud system comprising aplurality of horizontal floor and ceiling beams arranged in parallelspaced relationship and a plurality of vertical hollow studs extendingbetween the floor and ceiling beams. Each stud is formed to a similarcross-sectional configuration and each floor and ceiling beam isprovided with vertically aligned openings to receive the'top and bottomof the studs therein. Each aligned opening is positioned in rotativeangular relation to the final position of the stud when installed. Thestuds are provided with wedge-shaped notches at all corners about theperiphery of the stud near the tops and bottoms thereof to lock eachstud into the beam material after insertion and rotation through thepredetermined angle.

5 Claims, 12 Drawing Figures PATENTEUJUN 5191s 317236.714

sum 1 or 2 INVENTOR. J. FRED BRENNER BY M x.

ATTORNEY.

PATENIEUJUH 5 I975 SHEET 2 BF 2 FIG. 8

INVENTOR I J. FRED BRENNER BY FIG. IO

ATTORNEY.

WALL STUD SYSTEM BACKGROUND OF THE INVENTION The present inventionrelates generally to the field of building construction and moreparticularly is directed to a novel wall stud system capable of beingreadily assembled on the job without the need for external fasteners orspecial tools.

It has been the common practice to fabricate homes and other buildingsof relatively light construction with external bearing walls and floorand wall systems interconnected therewith. The floor members wereusually fabricated of relatively heavy floor joists of sufficientstrength and rigidity to support the finished floor surface. Prior artinterior walls were usually constructed of wooden stud members extendingfrom floor to ceiling. Such prior art wooden studs were usuallyfabricated of 2 by 3 inch or 2 by 4 inch stock which were nailed tofloor and ceiling structural members. Wall constructionmaterialscomprising either wire lath and plaster or a wall-board of the dry walltype was then nailed to the studs to form the usual finished wallsurface. In structures other than lightly constructed buildings such aslarge commercial and industrial buildings, it has been the usualpractice to incorporate only noncombustible'material in forming thefloor, ceiling and wall frame members. In such non-combustibleconstruction, it has been common practice to provide metal studscomprising sheet metal bent to channelshaped cross sectionalconfiguration for the wall framing. Such metal studs were usuallyemployed in systems which included a floor plate and a ceiling plate andmeans to fasten the metal studs in position. Once assembled, gypsum wallboard or metal lath could then be fastened directly to the metal studs,usually by employing sheet metal screws and automatic screw guns.

All of the prior art methods of building construction were quitetime-consuming and costly because of the large amount of manual laboremployed in both precisely laying out any system and also in the numberof man hours required to assemble the system. The vertical studs had tobe precisely located and then fastened in position by utilizing eithernails or screws. The studs had to be vertically aligned and horizontallyspaced, usually sixteen inches on center, all of which required a largeamount of skilled labor time. In view of the high costs of skilledconstruction workers, the former con struction methods resulted ingreatly increased construction costs.

SUMMARY OF THE INVENTION The present invention relates to a wall studsystem incorporating non-flammable members and means to precisely alignand automatically lock the members in position without the need forextended time-consuming measurements in the field or external fasteningdevices.

The system includes a floor beam and a ceiling beam of hollow, generallyrectangular configuration fabricated of sheet metal bent to the desireddimensions. One side of each of the floor and ceiling beams is punchedor otherwise treated to provide a plurality of shaped openings atequally spaced locations along the length of the beam. The openings areshaped to conform to the shape of cooperating stud members and arepositioned in angular rotation from the final position of the studs. Inthe case of studs of square cross sectional configurations, the rotativeangular disposition is 45.

A plurality of identical, elongated, hollow studs extend between thefloor and ceiling beams and are fabricated of dimensions suitable to fitwithin the openings in the beams. Wedge-shaped notches are provided inthe studs near each end thereof at all bent comers for locking purposeswithin the beam openings.

The studs position within the beam openings at an angular relationshipfrom the final position and respectively insert downwardly into thefloor beams and upwardly into the ceiling beam. With the studs assembledwithin the beam openings, the said wedge shaped notches are aligned withthe plane of the beam openings and then the studs are angularly rotatedwith respect to the beams. In this manner, the wedge-shaped notchestighten up upon the beam wall construction at the openings and lock thestuds into final position. When it is desired to utilize the wall studsystems in conjunction with finished wall materials such as lath or drywall sheets, the studs are designed to present one face thereof parallelto the surface of the lath or dry wall to thereby provide a straightsurface for connecting the wall construction materials in the usualmanner. Such a system has the advantage of requiring relatively littleprecision measurements or nailed connections in the field andsubstantially reduces the overall labor required in buildingconstruction. Additionally, the system is self-locking and does notrequire the use of nails, screws or other fasteners between the beam andstud members.

It is therefore an object of this invention to provide an improved wallstud system of the type set forth.

It is another object of the present invention to provide a novel wallstud system that incorporates interlocking beam and stud membersrequiring no additional fasteners.

It is another object of the present invention to provide a novel wallstud system employing hollow metallic floor beams and wall studs, thebeams being provided with a plurality of spaced openings to preciselyspace the studs with respect to the beams upon assembly:

It is another object of the present invention to provide a novel wallstud system that incorporates a plurality of two basic shapes, namelyhorizontal beams and vertical studs, the said studs inserting into thebeams and being rotated with respect therewith to lock the studs andbeams together.

It is another object of the present invention to provide a novel wallstud system incorporating horizontal beams and vertical studs andintegral means to lock the studs within the beams.

It is another object of the present invention to provide a novel wallstud system including upper and lower beam supports and decorative barmembers joining the supports, the bar members rotatively locking ontothe lower beam support.

Another object of the present invention is to provide a novel wall studsystem that is rugged in construction, inexpensive in manufacture, andtrouble-free when in use.

Other objects and a fuller understanding of the invention will be had byreferring to the following description and claims of a preferredembodiment thereof, taken into conjunction with the accompanyingdrawings, wherein like reference characters refer to similar partsthroughout the several views and in which:

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is an exploded perspective viewshowing the basic construction elements of the present invention.

FIG. 2 is an enlarged, fragmentary top plan view showing a vertical studof square configuration locked upon a horizontal base member.

FIG. 3 is a cross-sectional view taken along Line 3-3 of FIG. 2, lookinginto the direction of the arrows.

FIG. 4 is an enlarged, exploded, perspective view showing a modified,decorative stud and beam configuration.

FIG. 5 is a top plan view similar to FIG. 2 illustrating a modified studconfiguration.

FIG. 6 is a top plan view similar to FIG. 2, showing another modifiedstud configuration.

FIG. 7 is a top plan view similar to FIG. 2, another modified studconfiguration.

FIG. 8 is a partially assembled, perspective view showing a stud blankin the process of being formed into the final configuration.

FIG. 9 is a partial perspective view showing a portion of the wall studsystem in use.

FIG. 10 is a cross-sectional view taken along Line 10-40 of FIG. 9,looking in a direction of the arrows.

FIG. 11 is a fragmentary elevational view showing a modified beam andstud configuration.

FIG. 12 is an enlarged, fragmentary, top plan view similar to FIG. 2 andshowing a strengthening clip.

DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION Althoughspecific terms are used in the following description for the sake ofclarity, these terms are intended to refer only to the particularstructure of my invention selected for illustration in the drawings andare not intended to define or limit the scope of the invention.

Referring now to the drawings, I show in FIG. 1 the functionalcomponents of my invention including a generally rectangular, elongate,floor beam means 10 and a similar, generally rectangular, elongate,ceiling beam means 12 which is preferably installed in the same verticalplane as the floor beam 10 toprovide plumb vertical walls in conjunctionwith the studding as hereinafter more fully set forth. A plurality ofvertical, elongate, hollow studs 14 extend between the floor and ceilingbeams 10, 12 for wall construction purposes or decorative treatment ashereinafter more fully set forth.

Each floor and ceiling beam 10, 12 is preferably rectangularly formed toelongate hollow configuration and may be fabricated of thin, strongsheet material of the necessary rigidity for the use. I prefer to usesheet cold, rolled steel of one-sixteenth of an inch in thickness. Ifdesired, the material may be galvanized to prevent oxidation afterinstallation. It will be appreciated that other materials such as hardplastics and non-ferrous metals and sheet steel of other thicknesses maybe employed in accordance with the teachings of this invention for usewith specific applications. Each beam l0, 12 includes a base side l6, 18for firmly positioning against the respective floor 20 or ceiling 22 ofthe building under construction. The beams 10, 12 may be secured to thebuilding construction 20, 22 in a suitable, well known manner such as bygluing, nailing or other method. Optionally, the floor and ceiling beamsshowing It), 12, may be more strongly fabricated to be utilized asbearing members in accordance with well-known construction techniques tothereby become supports for other building construction members ashereinafter more fully set forth.

The inwardly facing side 24, 26 of each beam l0, 12 is punched orotherwise treated to provide a plurality of spaced stud receiving holes28, 30 for receiving and securing the vertical studs 14 therein.Preferably, the respective holes 28, 30 are horizontally spaced at 16inches on center to conform to usual construction industry installationprocedures. However, greater hole spacing or lesser hole spacing may beprovided and still come within the scope and meaning of this invention.

In the embodiment illustrated in FIG. 1, the holes 28, 30 are formed toa square configuration and communicate with the respective hollowinteriors 32, 34 of the beams 10, 12 for stud receiving and securingpurposes. As best seen in FIG. 2 the sides 36, 38 of the opening 28align at an angular relation of 45 to the longitudinal axis of the beam10. The hole 30 is similarly angularly aligned with the longitudinalaxis of the ceiling beam 12. It is the intent of this invention toinstall the respective floor and ceiling beams 10, 12 in vertical,spaced relationship so that the holes 30 vertically register above theholes 28 and with the sides of the holes 28, 30 in respective verticalalignment to readily receive the studs 14 during the system fabricationprocedure. Upon installation, as best seen in FIG. 3, the bottom 40 ofthe stud 14 inserts through the opening 28 and positions within thehollow interior 32 of the beam 10 in tight engagement with the inwardlyfacing side 24. Similarly, although not specifically illustrated, thestud top 42 inserts through the ceiling beam opening 30 and positionswithin the hollow interior 34 of the ceiling beam 12 upon installationand engagment.

As best seen in FIGS. 1 and 8, each stud means 14 is preferablyfabricated from a single sheet of material and is bent to a plurality ofidentical longitudinal folds 44 to define a plurality of vertical panels46, 48, 50 and 52. A tab 54 extends from the end panel 52 from the foldline 56 and serves to enclose the stud 14 by fastening upon the panel 46in well-known manner such as by spot welding or by sheet metal screws(not shown). In this manner, an elongate, enclosed stud 14 of relativelystrong construction can readily be fabricated using well-knowntechniques and conventional sheet material bending equipment. Ifdesired, the stud can be strengthened by providing a top 58 and a bottom60 which respectively insert through at the stud top and bottom 42, 40and secure therein in a well-known manner such as by spot welding. Thetop and bottom 58, 60 serve to strengthen the stud 14 when so desiredand prevent relative movement of the respective panels 46 48, 50, 52with respect to each other about the fold lines 44.

Each panel is provided near the top 42 and bottom tance for interactionwith the respective inwardly facing sides 26, 24 of the ceiling andfloor beams 12, 10. The legs 68, 70 outwardly extend from the respectivebases 66 and intersect at respective apices 72 of each triangularopening 62, 64. The apices 72 align over the respective fold lines 44for stud securing purposes so that the wedge-shaped openings 62, 64 arewidest at the fold lines 44. As best seen in FIGS. 1 and 8, eachtriangular opening 62, 64 bends about the fold lines 44 to form cornerpositioned notches having bases 66 at right angles to the longitudinalstud axis and generally wedge-shaped configuration opening toward therespective stud ends 40, 42.

Each stud 14 is fabricated of a plurality of sidewall panels 46, 48, 50,52 and is bent to a cross-sectional configuration to correspond with thecross-sectional configuration of the upper and lower beam holes 30, 28.The stud panels are fabricated slightly smaller than the dimensions ofthe openings 30, 28 to thereby permit each stud 14 to readily slide downinto the floor beam openings 28 and upwardly into the ceiling beamopenings 30.

In order to install the wall stud system in accordance with the presentinvention, the floor and ceiling beams 10, 12 are first secured tostationary building construction 20, 22 in well-known manner with therespective inwardly facing sides 24, 26 facing towards each other and invertical registry. The respective openings 28, 30 also are verticallyaligned in registry for receipt of the studs 14. The studs 14 arefabricated as hereinbefore explained and tie into the system by firstinserting each respective bottom end 40 into a floor beam opening 28, adistance sufficient to allow the stud top 42 to position directlybeneath the ceiling beam opening 30. The stud top 42 is then insertedinto the opening by vertically raising the stud until the upper notches74 horizontally align with the ceiling beam inwardly facing side 26. Thespacing between the stud upper and lower notches 74 is preciselycontrolled so that when the upper stud notch 74 horizontally aligns withthe inwardly facing side 26, the lower stud notch 74 similarly alignswith the inwardly facing side 24 of the bottom beam 10. See FIG. 3.

It will be appreciated that the upper and lower openings 30, 28 areangularly disposed at 45 from the longitudinal axis of the respectivebeams 12, 10. See FIG. 2. Accordingly, the studs 14 must also angularlyposition with regard to the longitudinal axis of the beams 10, 12 whenfirst inserted into the openings 28, 30. With the studs 14 so angularlypositioned, each stud in turn is rotated with respect to the beamsthrough an angle of 45". The upper and lower notches 74 rotate throughthe material of the respective inwardly facing sides 24, 26 and thewedge-shaped configuration serves to lock the studs 14 against theinwardly facing sides 24, 26. (FIGS. 2 and 3). By angularly turning thestuds 14 through 45, the respective stud panels 46, 48, 50, 52 will thenrotate into an alignment with the longitudinal axes of the beams 10, 12that is either parallel thereto with respect to two of said panels orperpendicular thereto with respect to the remaining two panels toprovide one flush, parallel surface 76 in alignment with thelongitudinal axis of the beams 10, 12 for receipt of the usual wallconstruction material such as rock lath, metal lath, or gypsum wallboard. It will be appreciated that after the studs are rotated withrespect to the upper and lower openings 30, 28, they will be securelylocked into position and cannot be removed from the beams 10, 12 untilfirst rotated back through the same 45 to thereby again allow relativevertical movement in the openings 30, 28.

Referring now to FIGS. 9 and 10, I show one method of installationwherein the ceiling beam 12 spaces above the floor beam 10. A pluralityof square crosssectional studs 14 rotatively lock in verticaly aligned,spaced relationship in the manner hereinbefore described to form a wallconstruction in conjunction with usual gypsmn wallboard 82. A pluralityof sheet metal screws 84 or other commonly employed fasteners turnthrough the wallboard 82 into the parallel stud surfaces 76 to therebysecurely affix the wall-board to the studs The room sides 88, 86 of thefloor and ceiling beams 10, 12 are similarly provided with a pluralityof square openings 28', 30 which rotatively position at an angle of 45with the longitudinal axes of beams 10, 12. Ceiling studs 14' and floorstuds 14" extend horizontally between adjacent floor beams 10 (only oneillustrated) and adjacent ceiling beams 12 (only one illustrated) in thesame manner as hereinbefore described for the wall studs 14. Ceilingwallboard 22 affixes to the ceiling studs 14' and conventional flooringmembers 20 affix to the floor studs 14' in the usual manner to form afin; ished appearance. The upper and lower edges 80, 82 of the wallboardabut respectively theceiling construction 22 and flooring 20 to formcorner junctions in wellknown manner. In one method of construction, ifdesired, the respective upper and lower openings 30, 28 may be carefullypositioned and the dimensions of the studs 14 may be controlled andfabricated to locate the parallel surfaces 76 of the stud 14 a distanceback from the room surfaces 86, 88 of the beams 12, 10, a distancecorresponding to the thickness of the wall board 82. Thus, if inchthickness wallboard is used, the parallel surfaces 76 of the studs 14should recess a distance of three-eights of an inch back from the roomsides 86, 88 of the beams 12, 10. Similarly, if 1% inch thicknesswallboard is utilized, the recess distance should be adjusted toone-half of an inch in depth see FIG. 10.

Referring now to FIG. 4, a modified type of stud construction is setforth wherein a decorative stud 90 is illustrated having eight sides. Itis contemplated that decorative studs may be utilized for room dividers,stair banisters, railings and other similar constructions where it isdesired to employ a decorative effect. Such decorative studs should befabricated of finished highly polished materials such as chrome coatedsteel or other finishes such as brushed brass to present a finishedappearance without covering or other decoration. In the mannerhereinbefore described, the floor and ceiling beams 10, 12 arefabricated to elongate, hollow form having shaped openings 92 ofconfiguration to receive the decorative studs 90 therein in lockingengagement.

Each stud includes a plurality of upper and lower corner, wedge-shapednotches 74 at each longitudinal fold 44' as hereinbefore set forth, forinteraction with the shaped openings 92 for locking purposes. It will beappreciated that as a decorative stud 90 is angularly turned withrespect to the upper and lower beams 10, 12, a portion of the shapedopenings 92 will be exposed by reason of the angular locking movement ofthe stud 90 with respect to the opening 92. If desired, a decorativeferrule 94 may be fabricated and slipped over the stud 90 prior toassembly of the parts. After the stud 90 is received within the opening92, the decorative ferrule 94 can be positioned against the beam 10 or12 to thereby form a decorative junction without any portion of theopening 92 being exposed. In the case of ceiling ferrules, set screws(not shown) may be employed in well-known manner to hold the ferruleagainst the underside of the ceiling beam 12.

As illustrated in FIGS. 5, 6 and 7, decorative studs may be formed toany of a number of pleasingly shaped configurations such as, forexample, triangular 96 (FIG. 6), hexagonal 98 (FIG. or elliptical 100(FIG. 7). It will be appreciated that similarly shaped cooperatingopenings 102, 104, 106, must be formed in the respective inwardly facingsides 24, 26 of the floor or ceiling beams 10, 12 in the mannerhereinbefore described to make a workable system. It will be furtherappreciated that many other variations of shaped studs may be employedin accordance with the teachings of this invention. All of the variouslyshaped studs secure to the upper and lower beams 12, in the mannerhereinbefore described by first inserting into the respective openings102, 104, 106 and then angularly rotating the studs with respect to thebeams to lock the upper and lower notches 44, 44' upon the beamconstruction. In observing the constructions of FIGS. 4, 5, 6 and 7, itwill be further appreciated that the angle of rotation of each stud withregard to its associated beams for locking purposes will vary dependingupon the number of sides or configuration of the stud. Also, the studsmust be symmetrical in cross-section with equal panels to effect uniformlocking upon the beams.

Referring now to FIG. 11, another detail of the present invention isillustrated wherein floor and ceiling beams 108 are fabricated to ahollow elongate configuration having side walls of sufficient thicknessand strength to form an integral part of the building structural bearingsystem. Such wall thicknesses and strength of beam may be readilycalculated in accordance with-well-known engineering practices to carryspecified loads such as floors or ceilings. It is contemplated that wallstuds 14 will insert downwardly through openings 28 in the mannerhereinbefore described and then rotate with respect to the openings tosecurely lock the studs 14 to the structural floor beams 108. Similarlyother wall studs 14 will insert upwardly into beam openings 28' formodular purposes for fabricating similar rooms on floors below. Byproperly supporting the beams 108 in accordance with well-knownconstruction techniques, a satisfactory bearing member can thus beprovided for receiving and securing floor systems such as floor studs14' thereon. Where modular construction below is contemplated, theceiling studs 14 can be secured to the beam 108 in the mannerhereinbefore set forth. Where more than one story construction isdesigned, the horizontal studs can serve both as floor studs 14" andceiling studs 14. In those instances, where buildings of fireproofconstruction are contemplated, all of the bearing members (not shown)supporting the strengthened beams 108 must be fabricated ofnon-combustible materials and the floor itself should also be fabricatedof non-combustible materials, all of which is in accordance withwell-known fireresistance construction techniques.

In order to facilitate field erection of modular buildings employing thepresent wall stud system, it is contemplated studs 14 could be modifiedto easily frame door and window openings by providing additional angularopenings (not shown) in the studs to receive horizontal and verticalframing members (also not shown) which would rotatively lock inaccordance with the teachings of the present disclosure.

Additionally, when building live and dead loads render it necessary ordesirable, angular clips 89 could be secured to the surface 24 of a beam10 with integral tabs 91 projecting away from the opening 28 for beamstrengthening purposes. If the loads to be supported were sufficientlygreat, one or more clips 89 could be located at the comers of theopening 28 as necessary to safely carry the load. See FIG. 12.

I claim:

1. In a wall stud system for use in building construction, thecombination of A. horizontal beam means of elongate configuration,

1. said beam means having an inwardly facing side being treated toprovide a plurality of spaced openings therethrough; and

B. stud means associated with the beam means and being respectivelyinwardly insertable into the said openings, 1. said stud means beingprovided with a plurality of inwardly positioned notches, a..'the saidnotches contacting the said inwardly facing side, b. the said notchesbeing wedge-shaped in configuration, 2. said stud means angularlyrotating with respect to the beam means to lock the said notches ontothe said side at the said openings.

2. The invention of claim 1 wherein the stud means are longitudinallybent to form a plurality of elongate panels which are defined bylongitudinal folds and wherein the said notches position about theperiphery of the stud means at each said longitudinal fold.

3. The invention of claim 2 wherein the stud means and the openings aretriangular in configuration in a horizontal plane.

4. The invention of claim 2 wherein the stud means and the openings arehexagonal in configuration in a horizontal plane.

5. The invention of claim 2 wherein the stud means and the openings areoctagonal in configuration in a horizontal plane.

1. In a wall stud system for use in building construction, thecombination of A. horizontal beam means of elongate configuration, 1.said beam means having an inwardly facing side being treated to providea plurality of spaced openings therethrough; and B. stud meansassociated with the beam means and being respectively inwardlyinsertable into the said openings,
 1. said stud means being providedwith a plurality of inwardly positioned notches, a. the said notchescontacting the said inwardly facing side, b. the said notches beingwedge-shaped in configuration,
 2. said stud means angularly rotatingwith respect to the beam means to lock the said notches onto the saidside at the said openings.
 2. said stud means angularly rotating withrespect to the beam means to lock the said notches onto the said side atthe said openings.
 2. The invention of claim 1 wherein the stud meansare longitudinally bent to form a plurality of elongate panels which aredefined by longitudinal folds and wherein the said notches positionabout the periphery of the stud means at each said longitudinal fold. 3.The invention of claim 2 wherein the stud means and the openings aretriangular in configuration in a horizontal plane.
 4. The invention ofclaim 2 wherein the stud means and the openings are hexagonal inconfiguration in a horizontal plane.
 5. The invention of claim 2 whereinthe stud means and the openings are octagonal in configuration in ahorizontal plane.